Boot for Promoting Healing of Foot/Hoof of an Animal and the Methods of Fabricating and Using the Boot

ABSTRACT

A form fit therapy boot along with methods of fabricating the boot for animals (including zoo animals, domestic animals and farm animals)to treat foot and/or hoof injuries is described. Embodiments of the boot permit the maintenance of a clean, reasonably sterile environment surrounding a wound or infection.

RELATED APPLICATIONS

This application is a Continuation Application of and incorporates byreference in its entirety U.S. patent application Ser. No. 14/951,947filed on Nov. 25, 2015 having the same inventors and title as thepresent application. U.S. patent application Ser. No. 14/951,947 furtherclaimed priority to and incorporated entirely by reference U.S.provisional patent application 62/085,175 filed on Nov. 26, 2014entitled “A Method of Treating the Feet/Hooves of Animals Including theProcess of Fabricating an Associated Boot and the Boot Itself” having atleast one common inventor as the present application.

BACKGROUND

Infections in or proximate a hoof or foot of an animal, includinglivestock, domestic animals and zoo animals can be difficult to treat.In the case of zoo animals, including Pachyderms generally andRhinoceroses specifically, an infected hoof is constantly andcontinually exposed to mud, dirt and even excrement, which hindershealing. Traditionally, an infected hoof often means eventual death foran infected Rhinoceroses.

Traditional bandaging or even boots, which can keep the infected areaclean and promote healing, are often not effective many animalsespecially larger and stronger animals, such the aforementionedRhinoceros and on the domestic side, horses, who through various meanswill often destructively remove the protective covering as it irritatesor bothers them. Accordingly, prior art methods involve repeatedlycleaning and disinfecting the hoof or foot and usually repeatedlyfighting any new infections that arise. Ideally, placing the affectedanimal in a cleaner environment free of potential containments wouldhelp, but practically this is often not possible especially with largeranimals. Even when kept in a much cleaner environment little can be doneto keep the animal away from its own excrement, which itself canaggravate an infection.

Ultimately, treating a hoof infection on large animals, and certain moremoderately sized animals as well, has involved a large amount of luck.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1a is an isometric front view of a boot for use on a hoofed animalaccording to a first embodiment of the present invention.

FIG. 1b is an isometric rear view of the boot for use on a hoofed animalaccording to the first embodiment of the present invention.

FIG. 1c is an isometric top view of the boot for use on a hoofed animalwith the boot splayed open to reveal the interior thereof according tothe first embodiment of the present invention.

FIG. 1d is an isometric partial close up view of the boot and inparticular the gaiter and a portion of the strap assembly according tothe first embodiment of the present invention.

FIG. 1e is an isometric partial close up view of the boot and inparticular the tread layer according to the first embodiment of thepresent invention.

FIG. 2a is an isometric front view of a boot for use on a hoofed animalaccording to a second embodiment of the present invention.

FIG. 2b is an isometric rear view of the boot for use on a hoofed animalaccording to the second embodiment of the present invention.

FIG. 2c is an isometric top view of the boot for use on a hoofed animalwith the boot splayed open to reveal the interior thereof according tothe second embodiment of the present invention.

FIG. 3 is a flow chart showing a first method of fabricating a facsimileof an animal's foot or hoof according to an embodiment of the presentinvention.

FIG. 4 is an isometric view of a silicone magnetic strip assembly usedin the first method of fabricating a facsimile of an animal's foot orhoof according to an embodiment of the present invention.

FIG. 5a is a flow chart showing a second method of fabricating afacsimile of an animal's foot or hoof according to an embodiment of thepresent invention.

FIG. 5b is a virtual three dimensional facsimile of an horse's leg/hoofwith calibrating pin shown according to an embodiment of the presentinvention.

FIG. 5c comprises virtual three dimensional oversized renderings of thehorse's leg/hoof with calibrating pin according to an embodiment of thepresent invention.

FIG. 5d comprises cross sectional views of three molds fabricated basedon the three oversized renderings according to an embodiment of thepresent invention.

FIG. 6a is flow chart showing a first method of fabricating a boot foran animal's foot or hoof using a facsimile of the foot or hoof accordingto an embodiment of the present invention.

FIG. 7a is flow chart showing a second method of fabricating a boot foran animal's foot or hoof using a facsimile of the foot or hoof accordingto an embodiment of the present invention.

FIG. 7b comprises cross sectional views of three molds fabricated basedon the three oversized renderings also including various portions of theboot fabricated by pouring/injecting resin into the boot according to anembodiment of the present invention.

DETAILED DESCRIPTION

Embodiments of the present invention or inventions comprises manydifferent aspects of a therapy boot and methods of fabricating the bootfor animals with foot or hoof injuries (including zoo animals, domesticanimals and farm animals). Embodiments of the boot permit themaintenance of a clean, reasonably sterile environment surrounding awound or infection.

Embodiments of the therapy boot are specifically form fit to aparticular animal's foot and/or leg. The boot, because it is fit nearlyexactly to the subject animal out of a soft and pliable elastomericmaterial, typically silicone, it does not irritate the animal as much asprior art boots and dressings. Further, because the boot is form fit andclose fitting, it is also much more difficult for the animal to removeit forcibly.

In use, the boot protects the foot from environmental contaminants suchas unsanitary water and fecal matter that may carry bacteria that couldinfect a wound or sore and hinder healing. Variations of the bootinclude water impervious breathable gaiters and/or fabric panels thatallow the foot to breath and maintain internal conditions suitable forhealing.

Terminology

The terms and phrases as indicated in quotation marks (“ ”) in thissection are intended to have the meaning ascribed to them in thisTerminology section applied to them throughout this document, includingin the claims, unless clearly indicated otherwise in context. Further,as applicable, the stated definitions are to apply, regardless of theword or phrase's case, to the singular and plural variations of thedefined word or phrase.

The term “or” as used in this specification and the appended claims isnot meant to be exclusive; rather the term is inclusive, meaning eitheror both.

References in the specification to “one embodiment”, “an embodiment”,“another embodiment, “a preferred embodiment”, “an alternativeembodiment”, “one variation”, “a variation” and similar phrases meanthat a particular feature, structure, or characteristic described inconnection with the embodiment or variation, is included in at least anembodiment or variation of the invention. The phrase “in oneembodiment”, “in one variation” or similar phrases, as used in variousplaces in the specification, are not necessarily meant to refer to thesame embodiment or the same variation.

The terms “couple” or “coupled,” as used in this specification andappended claims refers to an indirect or direct physical connectionbetween the identified elements, components, or objects. Often themanner of the coupling will be related specifically to the manner inwhich the two coupled elements interact.

The term “directly coupled” or “coupled directly,” as used in thisspecification and appended claims, refers to a physical connectionbetween identified elements, components, or objects, in which no otherelement, component, or object resides between those identified as beingdirectly coupled.

The term “approximately,” as used in this specification and appendedclaims, refers to plus or minus 10% of the value given.

The term “about,” as used in this specification and appended claims,refers to plus or minus 20% of the value given.

The terms “generally,” “near,” and “substantially,” as used in thisspecification and appended claims, mean mostly, or for the most part.

Directional and/or relationary terms such as, but not limited to, left,right, nadir, apex, top, bottom, vertical, horizontal, back, front andlateral are relative to each other and are dependent on the specificorientation of a applicable element or article, and are used accordinglyto aid in the description of the various embodiments and are notnecessarily intended to be construed as limiting.

As used herein, the term “elastomeric” is a used to describe a polymericmaterial having rubber-like properties i.e. an elastomer. The term isused to refer to materials that are both natural and synthetic rubbers.Some elastomeric materials that may be used herein in the fabrication ofthe therapy boots and some of the molds include but are not limited tosilicone and latex.

The term “resin” as used herein refers to an uncured polymeric materialtypically, but not always necessarily except when circumstances dictate,comprises a liquid.

The term “fibrous” is used herein to describe a material comprised offibers as can be used to reinforce the elastomeric material comprisingthe boot. The fibers of the fibrous material may be aligned and woveninto a fabric, they can comprise a mat consisting of randomly arrangedfibers, they can comprise unwoven fibers that are aligned in aparticular manner, or any combination thereof. possible reinforcingfibers include but are not limited to fiberglass, Nylon and Aramidfiber. The fibers can be treated, such as with a sizing, to facilitateadherence to the a particular resin.

The phrase “polymeric tread layer” refers to a layer of material havingproperties and characteristics making it more suitable than theunderlying elastomeric material comprising the boot's body to be incontact with the ground surface. In particular, the material is tougherand more wear resistant than the boot's elastomeric material. In severalembodiments of the present invention, a urethane materials is specifiedas the polymeric tread layer. Of particular note, the “polymeric treadlayer” need not have any particular pattern on the bottom side and maybe essentially smooth.

The phrase “form fit” as used herein refers to the fit of the bootrelative to the foot and in some embodiments the lower portion of theleg of a particular animal. Particularly, a “form fit” boot is one inwhich at least a portion of interior of the boot is constructed basedsubstantially and specifically on the form of the animal's foot and/orleg.

The term “gaiter” as used herein refers to the portion of an embodimentof the boot that extends above the portion or body of the bootcomprising the elastomeric material. Typically, the gaiter provides foradditional protection of the underlying leg and foot from potentialenvironmental contaminants, such as dirt, fecal matter and water. Insome embodiments when provided in conjunction with straps the gaiter mayalso be used to assist in securing the boot to the animal's foot andleg.

The phrase “breathable water impervious material, panel or fabric ”describes a material, or as used herein “a panel” comprised of such amaterial that allows gas such as air and water vapor to pass through itbut does not permit liquid water to pass therethrough. Gore-Tex fabricmade by W.L. Gore and associates is the trademark for such a material.

As used herein a “zipper assembly” refers to an assembly of right andleft sides that are joined by (i) a series of interlocking matingprojections, (ii) interlocking groove and ridge (i.e. a ziplock), or anyother equivalent structure that joins elongated left and right halvestogether.

As used herein, a “magnetic strip assembly” refers to a zipper-likedevice wherein the left and right sides, which also include outwardlyextending flanges, are joined together by magnets in place ofinterlocking mating projections or the like. In at least one variationconfigured for use with silicone resin, a series of rare earth magnetsare encapsulated in a silicone elastomer with the elastomer also formingthe left and right outwardly extending flanges.

The terms “foot” and “hoof” are used interchangeably herein and the useof one is not intended to exclude the other.

A First Embodiment of a Form Fit Therapy Boot for an Animal

FIGS. 1a-e illustrate a first embodiment of a therapy boot 100configured to protect the foot or hoof of an animal. the particularillustrations are of an embodiment of the boot form fit to the hoof of arhinoceros, although boots of similar design and construction aresuitable for use with many other animals including, but not limited to,other pachyderms, horses and dogs.

While variations are contemplated that are produced in several standardsizes for a particular type of animal, the illustrated embodiments andthe methods described herein pertain primarily to boots that are formfit specifically to a particular animal. Custom form fit boots fit aparticular animal more tightly and securely, and advantageously, reducethe probability that the animal will forcibly be able to remove theboots and exposed an injured foot to environmental contaminants.

The first embodiment boot 100 comprises the following primarycomponents: a body 105 comprised of an elastomeric material with panels110 of a breathable water impervious material provided in somevariations and including one or more zipper assemblies 125 to facilitateplacement and removal of the boot from the animal's foot; a toughpolymeric tread layer 115 covering the bottom side of the body; and aflexible, typically fabric, gaiter 120 extending upwardly from a topedge of the body to provide additional environmental protection.

In at least one variation, the elastomeric material comprising the body105 is silicone. The body can be formed in any suitable fashionincluding being brushed on a form or mold in resin form, or beinginjected or poured as a resin into a preconfigured mold cavity. Otherelastomeric materials can be used in place of silicone including latexand suitable formulations of urethane. Fillers can be added to the resinto strengthen and toughen it. For example, suitable fillers includefumed silica and short fibers of fiberglass, aramid or carbon.

Typically, but not necessarily, the body is comprised of two types ofsilicone; wherein, a thickness of material comprised of a supersoftsilicone, such as Ecoflex® supersoft rubber by Smooth-On, inc of EastTexas, Pa., is provided directly underneath an animal's foot to provideadditional cushioning. The primary silicone rubber utilized over thesupersoft silicone layer and for the sides of the boot is chosen toprovide the necessary strength and integrity to the boot. One suitablesilicone rubber resin is Smooth Sil 945 by Smooth-On, inc of East Texas,Pa.

The body 105 can be but is not necessarily reinforced with a continuousfibrous material in the form of a fabric or an unwoven mat. The fibermaterial can comprise fiberglass, nylon, aramid fiber or any othersuitable material. The fibrous material is usually encapsulated in theresin and hidden from view in the finished boot.

The body also typically includes one or more zipper assemblies 125 thatextend generally vertically from a top edge of the body to a pointcorresponding to a location where the leg transitions into a hoof orfoot on the animal intended to wear the boot. In the illustrated examplefor a rhinoceros, a pair of zipper assemblies are provided: one in therear or back of the body and one in the front of the body. Accordingly,a zookeeper can splay the boot open as generally illustrated in FIG. 1cto slip the boot easily over the animal's hoof and then zip the zipperassemblies closed to secure the upper portion of the boot around thelower portion of the leg. Of important note, the zipper assembly mayextend into the gaiter 120 as shown.

The zipper assemblies 125 may comprises any suitable configuration anddesign but in at least some variations the zipper assembly comprises awater resistant or waterproof zipper to provide further protection fromenvironmental contaminants coming into contact with the foot. In manyinstances, however, a standard zipper assembly is suitable since theprimary purpose of the boot is to keep the bottom portions of the footfrom coming into direct contact with dirty water.

The zipper assembly 125 can be attached to the body by a variety ofmeans but most often a combination of adhesive bonding to provide thebest possible seal and sewing to provide strength is used.

Provided on the left and right sides of the boot 100 are cutouts in thebody covered with panels 115 comprised of breathable water imperviousmaterial. Variations are possible that do not have the panels as arevariations that have only one panel, more than two panels and panels indifferent locations. The panels are typically sewn and adhesively sealedto the sides of the cutout.

In some variations of the body the interior of the boot is lined with afleece or similar material to enhance the fit of the boot, providemoisture wicking and improve comfort. The interior lining 135 is bestillustrated in FIG. 1 c.

Also provided on the body 105 near its top edge is a strap and buckleassembly 130. The strap is sewn to the body in one or more locations andprovides additional means to secure the boot to the leg proximate itsopening. Typically, a nylon or similar strap is provided with aclick-type buckle. In addition to helping seal and secure the top edgeopening of the boot around the animal's leg, it also acts to prevent thezipper pulls from working themselves downwardly thereby undoing thezipper assemblies 125 and loosening the boot by acting as a stopunderneath which the pulls cannot easily move.

Because the silicone elastomeric material comprising the body 105 oftendoes not have the abrasion resistance or toughness to withstand beingwalked on and run in especially on the type of terrain that might beencountered in the daily activities of an animal wearing the boot, atough abrasion resistant tread layer 115 is added to the bottom of thebody. As shown the layer rises above the bottom and covers a portion ofthe side of the boot's body as well.

The tread layer on the illustrated boot comprises polyurethane althoughother materials can be used as well. The tread layer is typicallyapplied to the boot after the body has been cured. In one variation, thetread layer can be added by one of several means including brushing onurethane resin, dipping the body in liquid urethane resin, formingsheets of semi-cured moldable resin around the body, or placing securinga fully cured cap over the bottom. When an uncured resin or partiallycured sheets are utilized the adhesive properties of the resin or sheetmay, but not necessarily, bond to the body during cure. However, becausemany silicone materials are notoriously difficult to get to bond withother materials, the top edge of the tread layer can be sewn to preventthe tread layer from peeling off even if the tread layer begins to orpartially delaminates from the underlying body.

Along the top edge of the body 105, a gaiter 120 typically comprised ofa breathable water impervious fabric is provided. As shown, the gaiteris comprised of left and right pieces that are joined together in use byway of the zipper assemblies 125 that continue from the top edge of thebody upwardly to the top edges of the gaiter pieces. The top edges ofthe gaiter pieces comprise an elastic strip that causes the top edge ofthe gaiter when the zipper assemblies are closed to encircle andmaintain contact with the leg of the animal. The gaiter adds a level ofprotection to the boot against the infiltration of debris into the boot.

A Second Embodiment of a Form Fit Therapy Boot for an Animal

FIGS. 2a-c illustrate a second embodiment of a therapy boot 200configured to protect the foot or hoof of an animal. The particularillustrations are of a boot form fit to the hoof of a rhinoceros,although boots of similar design and construction are suitable for usewith many other animals including, but not limited to, other pachyderms,horses and dogs.

The second embodiment boot differs from the first embodiment primarilyin the configuration of its body 205, which only extends upwardly overonly a portion of the foot instead of completely over the foot andupwardly onto the leg. Additionally, the second embodiment relies on agaiter 220 with associated strap assemblies 230 to help hold and securethe boot in place on an animal. Like the first embodiment boot, thesecond embodiment boot 200 comprises the following primary components:the body comprised of an elastomeric material; a tough polymeric treadlayer 215 covering most if not substantially all of the body; and thefabric gaiter, which extends upwardly from a top edge of the body andincludes one or more zipper assemblies 225 and strap assemblies 230.

In at least one variation, the elastomeric material comprising the body205 is silicone. The body can be formed in any suitable fashionincluding being brushed on a form or mold in resin form, or beinginjected or poured as a resin into a preconfigured mold cavity. otherelastomeric materials can be used in place of silicone including latexand suitable formulations of urethane. Fillers can be added to the resinto strengthen and toughen it. For example, suitable fillers includefumed silica and short fibers of fiberglass.

Typically, but not necessarily, the body is comprised of two types ofsilicone; wherein, a thickness of material comprised of a supersoftsilicone, such as Ecoflex® 50 supersoft rubber by Smooth-On, inc of EastTexas, Pa., is provided directly underneath an animal's foot to provideadditional cushioning. The primary silicone rubber utilized over thesupersoft silicone layer and for the sides of the boot is chosen toprovide the necessary strength and integrity to the boot. One suitablesilicone rubber resin is Smooth Sil 945 by Smooth-On, inc of East Texas,Pa.

The body 205 can be, but is not necessarily, reinforced with acontinuous fibrous material in the form of a fabric or an unwoven mat.The fiber material can comprise fiberglass, nylon, aramid fiber or anyother suitable material. The fibrous material is usually encapsulated inthe resin and hidden from view in the finished boot.

The gaiter 220, typically comprised of a breathable water imperviousfabric, extends upwardly from the top edge of the body to which it issecurely attached and sealed. As mentioned above the elastomeric body'stop edge usually terminates in a location proximate the side of the footof the animal for which it is made and the gaiter extends upwardly overthe remainder of the foot and over the lower portion of the leg. Asshown, the gaiter is comprised of left and right pieces that are joinedtogether in use by way of the zipper assembly 225 that begins proximatethe top edge of the body and continues to and often beyond the top edgesof the gaiter. In other variations, a single piece gaiter can be usedwith a single front, rear or side zipper assembly instead of two. Thetop edges of the gaiter pieces comprise an enclosed elastic strap thatcauses the top edge of the gaiter when the zipper assemblies are closedto encircle and maintain contact with the leg of the animal.

The zipper assemblies 225 may comprises any suitable configuration anddesign but in at least some variations the zipper assembly comprises awater resistant or waterproof zipper to provide further protection fromenvironmental contaminants coming into contact with the foot. In manyinstances, however, a standard zipper assembly is suitable since theprimary purpose of the boot is to keep the bottom portions of the footfrom coming into direct contact with dirty water.

The zipper assemblies 225 can be attached to the gaiter by a variety ofmeans but most often a combination of adhesive bonding to provide thebest possible seal and sewing to provide strength is used.

Upper and lower strap assemblies 230 are provided attached to the gaiterto assist in securing the boot to the animal. Typically, a nylon orsimilar strap is provided with a click-type buckle. In addition tohelping seal and secure the boot to the animal's leg, the upper assemblyalso acts to prevent the zipper pulls from working themselves downwardlythereby undoing the zipper assemblies and loosening the boot by actingas a stop underneath which the pulls cannot easily move.

In some variations of the body the interior of the boot is lined with afleece or similar material to enhance the fit of the boot, providemoisture wicking and improve comfort. The interior lining 235 is bestillustrated in FIG. 2 c.

Because the silicone elastomeric material comprising the body 205 doesnot typically have the abrasion resistance or toughness to withstandbeing walked on and run in especially on the type of terrain that mightbe encountered in the daily activities of an animal wearing the boot, atough abrasion resistant tread layer 215 is added to the bottom of thebody. As shown the layer rises above the bottom and covers a portion ofthe side of the boot's body as well.

The tread layer on illustrated boot comprises polyurethane althoughother materials can be used as well. The tread layer is typicallyapplied to the boot after the body has been cured. In one variation, thetread layer can be added by one of several means including brushing onurethane resin, dipping the body in liquid urethane resin, formingsheets of semi-cured moldable resin around the body, or securing a fullycured cap over the bottom. When an uncured resin or partially curedsheets are utilized the adhesive properties of the resin or sheettypically bond lightly to the body during cure. However, because manysilicone materials are notoriously difficult to get to bond with othermaterials, the top edge of the tread layer can be sewn to prevent thetread layer from peeling off even if the tread layer separates from theunderlying body.

A First Embodiment Method of Fabricating a Facsimile of an Animal'sFoot/Hoof

With reference to the flow chart of FIG. 3, the process of creating afacsimile of an animal's foot and lower leg is described. Initially, theanimal or at the very least the leg of the animal is immobilized asshown in block 305. Depending the type of animal and its temperament,this may require placing the animal under an anesthetic. In otherinstances, especially with domesticated animals, merely soothing theanimal may be sufficient.

As necessary, the animal's foot and lower portion of its leg may becoated with a suitable release agent or material that does not harm theanimal and does not hinder the cure of elastomeric resin, but alsoassists in the release of the cured elastomer from the foot. Possiblesuitable agents include wax and certain oils. In yet other instances,the portion of the leg and foot to be encapsulated is shaved to removefur that could otherwise hinder the success of the molding process.

Referring to block 310, an uncured elastomeric resin is brushed onto theanimal's foot and leg. Preferably a rapid cure silicone resin isutilized that cures to a solid consistency in 10 minutes or less andpreferably 5 minutes or less from the mixing of the resin with asuitable catalyst. The speed at which the resin cures often necessitatesmore than one person participating in the mold making process. Dependingon the consistency and type of resin utilized one or more layers may beapplied letting each layer at least partially cure before the next layeris added. Typically, however, the first layer or set of layers isintended to be relatively thin.

In block 315, one or more elongated magnetic strip assemblies 140 areplaced against the last layer of applied resin before it has had theopportunity to fully cure. A typical magnetic strip assembly isillustrated in FIG. 4. In particular, the left and right flanges 145 a&bhaving rare earth magnets 150 contained therein are pressed into thelayer to ensure they will adequately adhere to the resin. As is ofrelevance below, by pulling apart the strip at its longitudinallyextending magnetic interface 155 the left and right sections can beseparated.

Next as indicated in block 320, additional layers of resin are addedover the top of previously brushed and cured layers until the thicknessof the casting is considered sufficient. Care is taken to avoid brushingover the seam of the magnetic strip(s). In certain variations, pieces ofimpregnated fibrous material, such as a fiberglass fabric, is alsoplaced into, over and within the layers.

Referring to blocks 325 and 330, after all the layers have been addedwith or without reinforcement the mold is permitted to cure, anysilicone spanning the seam between the left and right sections of eachmagnetic strips is cut as necessary, the magnetic strips are separated,and the mold is removed from the animal's foot. Preferably, with the useof rapid cure resins, the entire foot molding process is completedwithin 30-60 minutes.

Once removed, the molding is prepared for the casting of a facsimile ofthe animal's foot by applying a suitable release agent as necessary andreconnecting the left and right sections of each magnetic strip. Asindicated in block 335, the facsimile is cast by pouring a suitablecasting material, such as plaster, into the mold and permitting theplaster to cure. Once cured, the sections of the magnetic strips areagain separated and the facsimile is removed.

To prepare the facsimile for boot fabrication as indicated in block 340,the surface of the casting is smoothed out through sanding removing anysharp edges or jutting portions that could cause discomfort to theanimal if reproduced in the boot. Once smoothed, the entire facsimile iscoated with epoxy resin to fill in any surface porosity and enhance thesurface integrity of the facsimile.

A Second Embodiment Method of Fabricating a Facsimile of an Animal'sFoot/Hoof

With reference to FIG. 5 a, a second method of creating a facsimile ofan animal's foot or hoof is described. As indicated in block 405, theanimals foot is scanned typically using a hand held scanner. The scannerpermits the animal's leg and foot to be scanned without sedating theanimal or fully immobilizing the animal's leg.

Using suitable software, the surface of the virtual foot and leg issmoothed and any scanning artifacts or other imperfections are removedand/or repaired as shown in block 410. With reference to block 415, avirtual calibrating pin of a predetermined size and configuration isadded near the top of the virtual foot and leg. FIG. 5b is anillustration of the rendered virtual leg 237 of a horse with thecalibrating pin 240 added thereto.

As indicated in block 420, modified renderings of the smoothed virtualfoot and leg are made that are larger than the virtual foot and leghaving selectively modified dimensions relative to the original virtualleg. With reference to FIG. 5c three oversized renderings of the horsesleg are illustrated. The first oversized virtual rendering 245 isgenerally the same size as the virtual foot and leg except for an addedthickness under the bottom of the foot. The second oversized virtualrendering 250 is uniformly larger than the first oversized rendering bya predetermined amount. The third oversized virtual rendering 255 islarger than the second oversized rendering primarily only in the regioncomprising the bottom of the foot and a portion of the sides of the footthat extend upwardly from the bottom thereof. Of note the dimensions ofthe calibrating pin 240 and the locations of the calibrating pin doesnot vary in each of the renderings.

With reference to block 425, the virtual foot and leg along with each ofthe oversized virtual renderings are 3D printed including thecalibrating pin of each creating the facsimile and three oversizedphysical renderings. As indicated in block 430, the prints are sanded toremove imperfections and smooth the surfaces thereof. A protective epoxycoating is also typically applied and once the coating has cured, asuitable release agent is applied to each of the facsimile and thephysical renderings.

With reference to block 435, female molds 260, 265 & 270 are createdusing each of the oversized renderings. the molds can be fabricatedusing any suitable means and materials; however, in one variation themolds are formed over each rendering using an epoxy putty, such as FreeForm® AIR Lightweight Epoxy putty made by Smooth-On, inc. of East Texas,Pa. Cross sectional views of the molds are shown in FIG. 5 d. Thefacsimile and the three female molds each of a progressively larger sizeare used to facilitate the fabrication of the form fit animal boot.

In one variation of the foregoing process, the female molds are directly3D printed eliminating the need to produce physical oversizedrenderings, as well as the need to create the female molds from amolding compound.

A First Embodiment Method of Fabricating a Form Fit Therapy Boot

With reference to the flow chart of FIG. 6A, one method of creating anembodiment of the form fit boot facsimile is described. This process canbe used to make a boot using either the plaster cast facsimile producedin the method described with reference to FIG. 3 or with a 3D printedfacsimile produced as part of the process described in FIG. 5A. As willbecome apparent, if a 3D printed facsimile is used with this process,there is no need to print the oversized physical renderings nor is therea reason to create the oversized female molds. Of further note, the useof the calibrating pin is not required on a 3D printed facsimile beingused with this method of boot fabrication.

Initially, a mold release of any suitable type, including silicone basedreleases and wax based releases, is applied to the facsimile asindicated in block 505.

In preparation for boot fabrication, the facsimile is typically invertedand attached to an appropriate supporting structure proximate the endopposite the foot portion. As shown in block 510, the bottom of the footon the facsimile is coated with layers of an elastomeric resin thatcures into a shock absorbing cushion on the boot's bottom. One suitableresin is Ecoflex® 50 supersoft rubber made by Smooth-On, inc. of EastTexas, Pa. Several layers of the coating can be applied as desired tobuild the cushioning layer up to a desired thickness.

Referring to block 515, once the cushioning layer has at least partiallycured, the sides and bottom of the facsimile is coated with a secondelastomeric resin, typically another silicone, having propertiessuitable for forming the body of the boot. One suitable resin comprisesSmooth Sil 945 by Smooth-On, inc. of East Texas, Pa. Multiple layers canbe brushed or toweled on to the facsimile to build the body up to adesired thickness.

In at least some variations as indicated in block 520, the body is alsoreinforced with a fibrous material. typically, the fiberous material,such as fiberglass cloth, is impregnated with liquid resin and thenpressed into place over the previously applied resin. The fiberousmaterial is then encapsulated in the resin when additional layers ofresin are applied to the facsimile as indicated in block 525. Once asufficient thickness of resin has been applied along with any desiredreinforcement, the resin is permitted to cure as indicated in block 530.In some variations, the boot is placed in an oven or heat box tofacilitate and/or speedup curing.

Once the curing of the boot is sufficiently complete with reference toblock 535 the body is removed from the facsimile. The body of the firstembodiment boot is cut along one or more generally vertically extendinglines from the top edge thereof to a location on the top side of thefeet. For the second embodiment boot, the body is typically cutcircumferentially around the side of the foot. The cuts permit removalof the boot body from the facsimile typically without destroying ordamaging the facsimile. As shown in block 540, ovular cutouts are madein one or more sides of the first embodiment body.

With reference to block 545, zipper assemblies 125 are sized, breathablewater impervious fabric panels 110 are cut and boot lining material 135,straps and buckles 130 and the gaiter 120 are prepared. As indicated inblocks 550: the two halves of the gaiter are sewn in place at the topedge of the body; the front and rear zippers are sewn to the sides ofthe vertically extending cuts in the body and along the edges of thegaiter halves; the one or more strap and buckle assemblies are sewn inplace; and the lining material is positioned and secured in the interiorof the boot. As applicable, the zipper assembly, the breathable waterimpervious panels and the gaiter halves can also be adhesively bonded tothe body to ensure a water tight seal.

To enhance the longevity of the boot especially when used by the animalin or on abrasive terrain, a tough wear resistant tread layer can beadded to the bottom of the boot that extends upwardly along its sides asis indicated in block 555. In at least one variation a polyurethaneresin is utilized. The resin in uncured liquid form is brushed onto thebottom of the body with successive layers being added until a desiredthickness is achieved. After at least partial cure the top edge of thetread layer is trimmed and then sewn in place over the body portionagainst which it was formed. Very few materials will bond to siliconeother than silicone itself, and wherein the tread layer is not silicone,sewing the tread layer to body prevents its separation therefrom.

A Second Embodiment Method of Fabricating a Form Fit Therapy Boot

With reference to the flow chart of FIG. 7A, one method of creating anembodiment of the form fit boot facsimile is described. Typically, thismethod utilizes the 3D printed facsimile and the associated molds (seeFIG. 5d ) produced pursuant to the second embodiment method offabricating a facsimile of an animal's foot/hoof as described above.

As indicated in block 605, the facsimile and associated molds areprepared for molding operation by sanding and smoothing the pertinentsurfaces and coating them with a suitable mold release. Next as shown inblock 610, the facsimile is placed in the first mold 260 using thecalibrating pins 240 to position and center the facsimile 275 therein.As indicated in block 615, a resin that will cure into a cushioningmaterial, such as Ecoflex® 50 supersoft rubber, is poured into the moldto fill the provided space between the bottom of the facsimile and thebottom surface of the mold cavity. The elastomer is permitted to cureand then the mold is opened and the facsimile with the cushioning layer280 attached is removed from the mold.

As indicated by block 620, the facsimile 275 with the cushioning layer280 attached is placed in the second mold 265 using the calibrating pins240 to position and center the facsimile therein. As indicated in block625, the body forming resin, such as Smooth Sil 945 by Smooth-On, inc.of East Texas, Pa., is poured into the mold to fill the provided spacebetween the bottom and sides of the combination of the facsimile and thecushion layer the bottom surface and side surfaces of the mold cavity.The elastomer is permitted to cure and then the mold is opened and thefacsimile with the boot body forming layer 285 attached is removed fromthe mold.

As indicated by block 630, the facsimile 275 with the cushioning layer280 and body layer 285 formed thereof is placed in the third mold 270using the calibrating pins 240 to position and center the facsimiletherein. As indicated in block 635, a polyurethane resin or other resinthat will cure into a toughened tread layer 290 is poured into the moldto fill the provided space between the bottom and immediately adjacentside surfaces of the body and the corresponding bottom surface andopposing side surfaces of the mold cavity. The tread layer resin ispermitted to cure and then the mold is opened and the facsimile with theformed boot is removed from the mold.

The boot produced using the second embodiment method does not includethe application of a fibrous reinforcement layer. Rather, a resin chosento comprise the body that has sufficient strength and other physicalproperties as to make the reinforcement layer unnecessary. In somevariations, a virgin resin itself may possess the necessary properties,but in other variations fumed silica, short cut fibers of fiberglass,aramid or carbon, or other fillers may be mixed with the resin toincrease its strength and toughness. Variations of the second embodimentmethod are also contemplated wherein additional step are incorporated inthe process perhaps incorporating a fourth mold wherein between theinsertion of the facsimile between second and third molds a layer orlayers of fibrous reinforcing material are applied to the surface of apartially formed boot body.

After removing the boot from the last mold, the boot is processed in amanner similar to the boot fabricated using the first embodiment method.The body of a first embodiment boot is cut along one or more generallyvertically extending lines from the top edge thereof to a location onthe top side of the feet. For the second embodiment boot, the body istypically cut circumferentially around the side of the foot. The cutspermit removal of the boot body from the facsimile typically withoutdestroying or damaging the facsimile. As shown in block 640, ovularcutouts are made in one or more sides of the first embodiment body.

With reference to block 645, zipper assemblies 125 are sized, breathablewater impervious fabric panels 110 are cut and boot lining material 135,straps and buckles 130 and the gaiter 120 are prepared. As indicated inblocks 650: the two halves of the gaiter are sewn in place at the topedge of the body; the front and rear zippers are sewn to the sides ofthe vertically extending cuts in the body and along the edges of thegaiter halves; the one or more strap and buckle assemblies are sewn inplace; and the lining material is positioned and secured in the interiorof the boot. As applicable, the zipper assembly, the breathable waterimpervious panels and the gaiter halves can also be adhesively bonded tothe body to ensure a water tight seal. The tread layer is also sewn tothe body typically proximate its top edge.

Treating an Animal Using Embodiments of the Boot

The boots can be adapted for use with a variety of animals and areparticularly advantageous for use with animals that are particularlyresistant to wearing foot coverings including traditional bandages andprior art boots. The form fit nature of the boot when properly securedto the foot or hoof using one or more straps and one or more zipperedclosures, makes it particularly difficult for most animals to remove.Furthermore, because of their form fitting nature, embodiments of theboots tend to be more comfortable than prior art solutions lessening theardor and determination an animal may apply in trying to remove theboots. Specific animals to which the boots may be used include, but arenot limited to, Pachyderms including rhinoceros, horses, and dogs.

Specifically concerning rhinoceros, they have been known to sufferdamage to their hooves. Often when exposed to a zoo environment, thehooves and surrounding tissue have been known to become infected, whichhas proven very difficult to cure as long as the animal remains exposedto the conditions that gave rise to the infection in the first place.Often such an infection can be life threatening. The boots describedherein provide a means for maintaining the cleanliness of the hoof andfoot and permit healing without undue risk of a life threateninginfection.

The boots can be quickly placed on and removed from an animal making itpossible to use the boots with moderately cooperative zoo animalswithout sedation.

To install either the first or second embodiment boot, the front andback zippers are opened and the sides of the boot are splayed apart. Insome variations a gel insert insole can be added to further cushion aninjured foot. The boot is placed over the applicable foot of the animaland the zippers are closed to secure the boot to the foot. Thestrap/buckle assemblies are secured and adjusted to further secure theboot to the foot. For example, when used on a cooperative rhinoceros,the boot can be applied in a about 10 minutes or so permitting its easyremoval and re-application as necessary in the treatment of the foot.

Variations and Other Embodiments

The various embodiments and variations thereof, illustrated in theaccompanying Figures and/or described above, are merely exemplary andare not meant to limit the scope of the invention. It is to beappreciated that numerous other variations of the invention have beencontemplated, as would be obvious to one of ordinary skill in the art,given the benefit of this disclosure. All variations of the inventionthat read upon appended claims are intended and contemplated to bewithin the scope of the invention.

We claim:
 1. A form fitting therapy boot for the foot of an animal, thetherapy boot comprising: a body comprised of an elastomeric material,the body including a foot pad, and a side wall extending upwardlyconfigured to surround and cover at least a portion of the foot; apolymeric tread layer covering the bottom of the body and extendingupwardly at least partially over the side of the body; and a fabricgaiter, the gaiter coupled to the body proximate a top edge andextending upwardly from the top edge, the gaiter comprising a waterproof flexible material.
 2. The therapy boot of claim 1, wherein aninterior of the body is form fit to the animal.
 3. The therapy boot ofclaim 1, wherein the body includes generally vertically extending frontand rear zipper assemblies.
 4. The therapy boot of claim 1, wherein thebody includes at least one generally vertically extending zipperassembly.
 5. The therapy boot of claim 1, including at least onebreathable water impervious panel covering at least one cutout in thebody.
 6. The therapy boot of claim 5, wherein the at least onebreathable water impervious panel includes left and right panelscovering left and right cutouts of the at least one cutout respectively.7. The therapy boot of claim 1, wherein the elastomeric materialcomprises silicone.
 8. The therapy boot of claim 1, wherein the bodyfurther includes fiberous reinforcement.
 9. The therapy boot of claim 8,wherein the fibrous reinforcement comprises nylon.
 10. The therapy bootof claim 1, wherein the polymeric tread layer comprises polyurethane.11. The therapy boot of claim 1, further including a first strap andbuckle assembly proximate a top edge of the gaiter and extending aroundthe gaiter.
 12. The therapy boot of claim 11, further including a secondstrap and buckle assembly extending around the gaiter below the firststrap and buckle assembly.
 13. The therapy boot of claim 1 beingconfigured to conform to one of the foot of a horse, pachyderm, and dog.14. A form fitting therapy boot for the foot of an animal, the therapyboot comprising: a body form fit to the foot of the animal comprised ofsilicone reinforced, the body including, a foot pad, a side wallextending upwardly from the foot pad configured to surround and cover atleast a portion of the sides of the foot, a generally verticallyextending water resistant front zipper assembly, a generally verticallyextending water resistant rear zipper assembly, a left side cutoutcovered with a breathable water impervious panel, and a right sidecutout covered with a breathable water impervious panel.
 15. The therapyboot of claim 14, wherein the body further includes fiberousreinforcement.
 16. The therapy boot of claim 14, further comprising afabric gaiter, the gaiter coupled to the side wall proximate a top edgethereof and extending upwardly from the top edge, the gaiter comprisinga water proof flexible material.
 17. The therapy boot of claim 16,further including a first strap and buckle assembly proximate a gaitertop edge of the gaiter and extending around the gaiter.
 18. The therapyboot of claim 17, further including a second strap and buckle assemblyextending around the gaiter below the first strap and buckle assembly.19. The therapy boot of claim 14 being configured to conform to one ofthe foot of a horse, pachyderm, and dog.
 20. The therapy boot of claim14 being configured to conform to the hoof of a rhinoceros.